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Overview of Materials Research at NASA Marshall Space Flight Center
Tracie Prater, Ph.D.Aerospace Engineer, Materials and Processes Laboratory
NASA Marshall Space Flight CenterHuntsville, AL
Barnard‐Seyfert Astronomical SocietyDecember 17th, 2014
https://ntrs.nasa.gov/search.jsp?R=20150002635 2020-07-21T19:19:04+00:00Z
About MeOriginally from Hazard, Kentucky
B.S. Physics from EKUM.S., Ph.D. Mechanical Engineering from Vanderbilt
Previously worked as a materials engineer at United Launch Alliance (ULA)
currently an aerospace engineer in the Materials and Processes Laboratory at NASA Marshall Spaceflight Center
Then…..
Now
NASA Around the Country
A Brief History of NASA MSFC
1945 Project Paperclip 1950 German team moves to Redstone Arsenal to work for ABMA on development of Redstone Rocket
October 4, 1957 Sputnik launch
December 6, 1957 Vanguard explosion
January 31, 1958Redstone Rocket puts Explorer I in orbit
A Brief History of NASA MSFC
1960 Eisenhower signs act creating civilian space agency 1960‐1972 MSFC develops Saturn V
1973‐1979 Skylab 1981‐2011 Space Shuttle
A Brief History of NASA MSFC
1998‐present International Space Station
1990‐present Hubble Space Telescope
Space Launch System (SLS) James Webb Space Telescope
NASA’s Four Core Mission Areas
Science Space Technology
Human Exploration and Operations Aeronautics
Human Spaceflight Architecture
Space Launch System (SLS) Initial lift capacity of 70 MT, evolvable to 130
MT Carries the Orion Multipurpose Crew Vehicle
(MPCV) First flight of SLS in 2017
Materials Research at NASA MSFC
What materials are used for aerospace structures?
Metals‐Aluminum‐Steel/stainless steel‐Titanium‐Magnesium‐Superalloys
Ceramics Plastics/Elastomers Composites
Composite CryotankNASA needs an affordable, lightweight vehicle for greater payload capability to enable future exploration missions.
Composite cryotanks could lead to rocket propellant tanks that achieve greater than 30% weight savings and 25% cost savings compared to the state-of-the-art metal tanks.
Revolutionary manufacturing capabilities (automated fiber placement, out of autoclave cure) with innovative composite materials enable low cost, higher performance cryogenic tankage.
Friction Stir Welding
Friction stir welding‐welding process that does not melt the material‐produces high‐strength, defect‐free joints‐completely robotic process‐used for almost all launch vehicle primary structures and habitable modules‐largest vertical weld tool ever constructed for SLS barrel panel welds at MAF
Friction Stir Welding at MichoudAssembly Facility for SLS
Additive Manufacturing
For S
pace
Near-Term
In-S
pace
Long-Term
Why Additive Manufacturing?Affordability‐reduced part count‐fewer critical welds and brazes‐reduced tooling‐schedule and cost savings
Performance‐Optimized internal flow passages‐Minimized leak paths‐Lower mass
Additive Manufacturing: Metals Propulsion components manufactured using Selective Laser Machining (SLM)
atomized metal powder fused by laser‐Inconel, Titanium
Hot fire testing and burst testing for validation Immense potential to reduce cost and development life cycle for propulsion
systems Uncertainty in how additively manufactured parts compare to conventionally
manufactured counterparts MSFC’s role is primarily development of certification path and standards
3D Printing in Space
Caps
Threads
Buckles
Clamps
Springs
Potential Mission Accessories
Containers
The 3D Print project will deliver the first 3D printer on the ISS and will investigate the effects of consistent microgravity on melt deposition
additive manufacturing by printing parts in space.
The 3D Print project will deliver the first 3D printer on the ISS and will investigate the effects of consistent microgravity on melt deposition
additive manufacturing by printing parts in space.
Melt deposition modeling: 1) nozzle ejecting molten
plastic, 2) deposited material
(modeled part), 3) controlled movable table
3D Print SpecificationsDimensions 33 cm x 30 cm x 36 cmPrint Volume 6 cm x 12 cm x 6 cmMass 20 kg (w/out packing material or
spares)Est. Accuracy 95 %Resolution .35 mmMaximum Power 176W (draw from MSG)Software MIS SliceRTraverse Linear Guide RailFeedstock ABS Plastic
Materials Joining in Space Space structures are increasingly
susceptible to MMOD and collisions with other hardware – current risk is low, but could be catastrophic
Welding would enable a rapid repair capability and versatile means of on‐orbit assembly
Offers advantages over mechanical fasteners and adhesives:‐reduced weight‐improved mechanical properties‐reduced stress concentrations‐increased rigidity
A Brief History of In‐Space Welding
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A Vision of In‐Space Manufacturing
‐In‐space fabrication and repair of plastics using 3D printing‐Qualification/inspection of on‐orbit parts using structured light scanning‐Printable small satellite technologies‐On‐orbit plastic feedstock recycling‐In‐space metals manufacturing process demonstration‐Welding in space‐Additive construction using regolith
Materials in the Space Environment: MISSE
MISSE: Materials International Space Station Experiment
Material samples mounted externally on the Kibo module (JAXA) of the ISS
Samples are exposed to the space environment for up to two years, then downmassed for testing and analysis
Experiments evaluate material degradation in the space environment‐atomic O2
‐UV radiation
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Nuclear Propulsion Fuel Development
‐NASA’s Nuclear Cryogenic Propulsion Stage Project was started in to assess the affordability of Nuclear Thermal Propulsion‐NTP is a game changing technology for space exploration
Fewer launches, reduced trip times, increased payloads‐Goal of overall NTP tasks
Fuel fabrication and testingDesign and architecture integrationAffordable engine qualification
‐Critical need for nuclear fuels developmentLack of qualified fuel material is a key risk
‐MSFC currently developing critical fuel fabrication capabilities using full scale fabrication and testing
Enable future fuel optimizationBuy down risk for future engine ground testing
‐Highly integrated NASA and DOE team
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Nuclear Propulsion Fuel Development
‐Graphite based fuel materialsFull scale engines demonstrated during ROVER/NERVA program in 1960’sPrevious M&P capabilities do not exist
‐CERMET fuel materialsInvestigated in 1960‐70’s to provide improved performance over graphite materials, but not provenNo “qualified” materials or fabrication processesCritical materials and process capabilities do not exist
‐ObjectivesRecapture graphite fuels and fabrication capabilityDevelop W‐UO2 CERMET fuels fabrication capabilityCharacterize microstructure, properties, and performancePerform subscale and full scale fuel element testing
Rover/NERVA Graphite Fuel Elements
W/ZrO2
W Clad
W/ZrO2 CERMET(MSFC HIP fabrication)
Solar Sails
‐solar sails exploit solar pressure to provide a means of propulsive energy‐sail material is typically a very thin (~micrometers) aluminum (or aluminized) film: Kapton, Mylar, Alumina‐material selection drivers for solar sails: degradation in space environment, weight, operating temperature range, fabrication (manufacturing), reflection and emissivity‐solar sail missions: IKAROS (JAXA, 2010), NEAScout, Lunar Flashlight
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Questions
Tracie Prater, Ph.D.Aerospace Engineer, Materials and Processes LaboratoryNASA Marshall Space Flight Centertracie.j.prater@nasa.gov
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